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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Effects of Traveling Magnetic Field on Dynamics of Solidification

TMF is based on imposing a controlled phase-shift in a train of electromagnets, forming a stack. Thus, the induced magnetic field can be considered to be travelling along the axis of the stack. The coupling of this traveling wave with an electrically conducting fluid results in a basic flow in a form of a single axisymmetric roll. The magnitude and direction of this flow can be remotely controlled. Furthermore, it is possible to localize the effect of this force field though activating only a number of the magnets. This force field generated in the fluid can, in principle, be used to control and modify convection in the molten material. For example, it can be used to enhance convective mixing in the melt, and thereby modify the interface shape, and macrosegregation. Alternatively, it can be used to counteract thermal and/or solutal buoyancy forces. High frequency TMF can be used in containerless processing techniques, such as float zoning, to affect the very edge of the fluid so that Marangoni flow can be counter balanced. The proposed program consists of basic fundamentals and applications. Our goal in conducting the following experiments and analyses is to establish the validity of TMF as a new tool for solidification processes. Due to its low power consumption and simplicity of design, this tool may find wide spread use in a variety of space experiments. The proposed ground based experiments are intended to establish the advantages and limitations of employing this technique. In the fundamentals component of the proposed program, we will use theoretical tools and experiments with mercury to establish the fundamental aspects of TMF-induced convection through a detailed comparison of theoretical predictions and experimental measurements of flow field. In this work, we will conduct a detailed parametric study involving the effects of magnetic field strength, frequency, wave vector, and the fluid geometry. The applications component of this work will be focused on investigating the effect of TMF on the following solidification and pre-directional solidification processes: (1) Bridgman growth of Ga:Ge with the goal of counteracting the buoyancy-driven convection; (2) Mixing of Pb-Ga and Pb-Sn alloys with the aim of initiating and maintaining a uniform melt prior to solidification processing; and (3) Float Zone growth with the aim of identifying, through simulations and model experiments, conditions needed to counteract Marangoni flow in a microgravity environment. The proposed research has strong relevance to microgravity research and the objectives of the NRA. TMF can provide a unique and accurate mechanism for generation and control of desirable flow patterns for microgravity research. These attributes have significant relevance to 1) Alloy mixing prior to solidification in a microgravity environment. TMF can provide this mixing with a low level of power consumption; (2) TMF can offset the deleterious effects of Marangoni convection in microgravity containerless processing. Thus, TMF can be instrumental in further understanding this phenomena; (3) Generation of controlled flows will allow the investigation of the effect of these flows on growth morphology and growth kinetics; and (4) On Earth, TMF has the potential to significantly counter-balance thermosolutal convection, thereby creating conditions similar to those obtained in microgravity. Once demonstrated, this new tool for use in solidification has the strong potential to find applications in a host of microgravity material research projects.

Mazuruk, Konstantin↗
NASA NTRS2003

Minimizing Segregation during the Controlled Directional Solidification of Dendric Alloys

Gravity-driven convection induced in the liquid by density gradients of temperature or composition disrupts uniform dendritic growth during controlled directional solidification and promotes severe macrosegregation. The solute-rich region about the dendrite tip appears to play a pivotal role in channel initiation. Allen and Hunt referred to this region as an "initial transient" or dynamic region constituting steep concentration gradients. Experimental investigation also point to the role the tip region plays in developing microstructure. Hellawell and co-workers showed that flow-through dendritic channels could be effectively disrupted, and segregation minimized, during the gradient freezing of bulk castings by rotating the melt through a slight angle with respect to Earth's gravity vector. Adapting this principle to controlled directional solidification, it has been shown" that segregation in dendritic alloys can be minimized, and properties improved, by processing the sample near horizontal in conjunction with a slow axial rotation of the crucible. It is postulated that the observed microstructural uniformity arises by maintaining the developing solute field about the dendrite tip. Solute rejected during vertical directional solidification will rise or sink parallel to the primary dendrite arms during axial rotation setting the stage for accumulation, instabilities, and segregation. In contrast, during horizontal growth, the rejected solute will sink or rise perpendicular to the primary dendrite. Now, in the presence of a slight axial rotation, solute that was initially sinking (or rising) will find itself above (or below) its parent dendrite, i.e., still about the tip region. The following is intended to experimentally demonstrate the viability of this concept in coordination with a model that gives predictive insight regarding solute distribution about growing dendrites. Alloys based on the lead-tin eutectic system were used in this study. The system is well characterized, the constituent metals are available in a very pure form, and the thermophysical properties are well known. During solidification of hypoeutectic alloys, e.g., 55 wt pct Pb, the primary dendrites reject the less dense tin, and for the hypereutectic alloys, e.g., 75 wt pct Sn, the primary dendrites reject denser lead. Alloys were prepared by melting appropriate amounts of lead and tin in a glass crucible after which the homogeneous liquid was sucked directly into 5-mm i.d. glass tubes. The sample tube, containing approximately 30 cm of alloy, was then mechanically driven into the directional solidification furnace assembly and positioned such that approx. 20 cm of the sample was remelted. Subsequently, directional solidification was initiated by withdrawing the sample through a water-cooled jacket at a constant growth velocity of 2 ,microns/s. After 5 to 6 cm of growth, the sample was quickly removed from the furnace and quenched in a water bath to preserve the solid-liquid interface. Samples were directionally solidified vertically upward, nearly horizontally, and some in conjunction with an applied axial rotation of the crucible. Temperature gradients at the solid-liquid interface were measured with an in-siru K-type thermocouple. Solidified samples were cut perpendicular and parallel to the growth direction and conventionally prepared for microscopic examination.

Grugel, Richard N.↗
DOE OSTI2018

Experimental Investigations on Solidification of 500-kg Steel Ingots with Laboratory Trials

The present work focuses on the solidification process of large steel ingots. Several complex solidification phenomena in large ingots were investigated by means of experimental hot modeling and cold modeling. In hot modeling, a 500 kg ingot solidified slowly in a specially insulated mold and this slow solidification process simulates the solidification of industrial scale ingots with a weight between 3 and 6 t. Temperature was measured by thermocouples during solidification and curves were plotted, and as-cast structure and macrosegregation of alloying elements were quantified. The A segregates were produced in the laboratory hot trials and quantitatively investigated. Meanwhile, water modeling (cold modeling) using NH{sub 4}Cl solution was conducted with different cooling/heating conditions. Macroscopic crystal growth phenomena, such as dendritic growth, sedimentation of crystals, and convective fluid flow, were directly observed and analyzed, and flow channels were also observed and compared with A segregates in the hot modeling.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Thermoelectric Magnetic Convection on Shrinkage Porosity at the Final Stage of Solidification of GCr18Mo Steel Under Axial Static Magnetic Field

Adopting effective strategies to eliminate the shrinkage porosity at the final stage of steel solidification is one of the most attractive research subjects for metallurgists. Despite the progress in understanding the thermoelectric magnetic convection (TEMC) in the solidification process, utilization of TEMC for modifying the solidification feeding of steel has been ignored. The effects of TEMC on the shrinkage porosity at the final stage of solidification of GCr18Mo steel were investigated under an axial static magnetic field (ASMF). The morphology and porosity of GCr18Mo steel were investigated quantitatively by X-ray microtomography. We found that the amount of porosity first decreases and then increases with increasing intensity of the ASMF. Meanwhile, the shape of the porosity changed from tortuous to elliptic under the ASMF. On the basis of both the experimental and simulated results, the decrease in porosity is attributed to an adequate development of the TEMC leading to sufficient feeding. This study sheds light on an alternative technique for eliminating the shrinkage porosity at the final stage of steel solidification in industrial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Characterization of Solidification Microstructures in Vacuum Arc Remelted Nickel Alloy 718

Digital image analysis techniques were developed to autonomously characterize dendritic solidification features in microstructures of a nickel alloy 718 ingot produced by vacuum arc remelting (VAR). Automated macrophotography was implemented to image microstructures and produce large image montages of etched ingot cross sections. Two image analysis techniques, particle identification and two-point correlation, were applied to autonomously measure primary dendrite arm orientation and secondary dendrite arm spacing from the image montages. Particle identification measured individual dendritic features. The two-point correlation technique measured averaged feature values over defined image areas. These methods are described and compared. Melt pool profile and solidification time histories were reconstructed from primary dendrite arm orientation and secondary dendrite arm spacing measurements, respectively. These characterization techniques provide two new methods of reconstructing melt pool profiles and solidification times in cast ingots. The information produced is expected to be useful in the validation of computational models for solidification during VAR, similar remelting processes, and general casting processes that produce dendritic solidification features.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Diffusion Length in Modeling of Equiaxed Dendritic Solidification under Buoyancy Flow in a Configuration of Hebditch–Hunt Experiment

Modeling of equiaxed solidification is vital for understanding the solidification process of metallic alloys. In this work, an extended literature review is given for the models currently used for equiaxed solidification simulations. Based on this analysis, we present a three-phase multiscale equiaxed solidification model in which some approximations regarding solute transport at microscopic scale are put together in a new way and incorporated into macroscopic transport equations. For the latter, a term relating to the momentum exchange between the two phases is revised, and a modification for the grain packing algorithm is proposed. A modernized model for equiaxed dendrite growth is tested using a case of solidification of Sn-5 wt pct Pb alloy in a parallelepiped cavity that mimics the Hebditch–Hunt experiment. The results obtained using two approaches to calculate diffusion length are presented and compared both with each other and with numerical results from elsewhere. It is demonstrated that diffusion length has a crucial effect on the final segregation pattern.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Integrated System of Thermal/Dimensional Analysis for Quality Control of Metallic Melt and Ductile Iron Casting Solidification

The main objective of the present work is to introduce a specific experimental instrument and technique for simultaneously evaluating cooling curves and expansion or contraction of cast metals during solidification. Contraction/expansion analysis illustrates the solidification parameters progression, according to the molten cast iron characteristics, which are dependent on the melting procedure and applied metallurgical treatments, mold media rigidity and thermal behavior [heat transfer parameters]. The first part of the paper summarizes the performance of this two-mold device. Its function is illustrated by representative shrinkage tendency results in ductile cast iron as affected by mold rigidity (green sand and furan resin sand molds) and inoculant type (FeSi-based alloys), published in part previously. The second part of the paper illustrates an application of this equipment adapted for commercial foundry use. It conducts thermal analysis and volume change measurements in a single ceramic cup so that mold media as well as solidification conditions are constants, with cast iron quality as the variable. Experiments compared gray and ductile cast iron solidification patterns. Gray iron castings are characterized by higher undercooling at the beginning and at the end of solidification and lower graphitic expansion. Typically, ductile cast iron exhibits higher graphitic, initial expansion, conducive for shrinkage formation in soft molds.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Interface morphology and dislocation-mediated processes during rapid solidification of thin films

Rapid solidification experiments have, in recent years, revealed a wealth of new microstructural phenomena that suggest a strong connection between the kinetics of solidification and the crystalline structures that emerge as a result. In this work, we investigate the interplay between interface morphology and defect-mediated processes during rapid solidification conditions using a Phase Field Crystal (PFC) model, enabling us to simultaneously and efficiently explore the physics of solidification and elasto-plasticity in the formalism of a single-field theory. We predict that there are two mechanisms by which dislocations emitted directly from the solid–liquid interface induce orientation gradients as well as the formation of subgrain boundaries within a single solidifying cell. We relate these mechanisms to the morphology of the moving solid–liquid interface and identify a suitable control parameter in the PFC model with which we can go between said morphologies by effectively changing the relative strength of the capillary length and kinetic coefficients of the solid–liquid interface. Thus, we are able to provide mechanistic explanations for several microstructural features (with an emphasis on orientation gradients and subgrain boundaries) observed during the rapid solidification of pure materials. We also provide a simple explanation for the formation of “jagged” subgrain boundaries, which is consistent with our experimental observations in rapidly solidified samples of Aluminum, whose mechanisms have thus far been unknown.

Interface morphology↗
DOE OSTI2016

Modeling of heat transfer, fluid flow and solidification microstructure of nickel-base superalloy fabricated by laser powder bed fusion

Laser-Powder Bed Fusion (L-PBF), an additive manufacturing process, produces a distinctive microstructure that closely resembles the weld metal microstructure but at a much finer scale. The solidification parameters, particularly temperature gradient and solidification rate, are important to study the as-built microstructure. In the present paper, a computational framework with meso-scale resolution is developed for L-PBF of Inconel ® 718 (IN718), a Ni-base superalloy. The framework combines a powder packing model based on Discrete Element Method and a 3-D transient heat and fluid flow simulation. The latter, i.e., the molten pool model, captures the interaction between laser beam and individual powder particles including free surface evolution, surface tension and evaporation. The solidification parameters, calculated from the temperature fields, are used to assess the solidification morphology and grain size using existing theoretical models. The IN718 coupon built by L-PBF are characterized using optical and scanning electron microscopies. Finally, the experimental data of molten pool size and solidification microstructure are compared to the corresponding simulation results.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Solidification characterization of a new rapidly solidified Ni-Cr-Co based superalloy

The solidification characterization of a new rapidly solidified Ni-Cr-Co based superalloy prepared by plasma rotating electrode process was investigated by means of optical microscope, scanning electron microscope, and transmission electron microscope. The results show that the solidification microstructure changes from dendrites to cellular and microcrystal structures with decreasing powder size. The elements of Co, Cr, W and Ni are enriched in the dendrites, while Mo, Nb and Ti are higher in the interdendritic regions. The relationships between powder size with the average solid-liquid interface moving rate, the average interface temperature gradient and the average cooling rate are established. Microsegregation is increased with larger powder size. The geometric integrity of MC Prime type carbides in the powders changes from regular to diverse with decreasing powder size. The morphology and quantity of carbides depend on the thermal parameters and non-equilibrium solute partition coefficients during rapid solidification. - Highlights: Black-Right-Pointing-Pointer The relations of solidification thermal parameters with powder size are established. Black-Right-Pointing-Pointer The relation of non-equilibrium solute partition with powder size is investigated. Black-Right-Pointing-Pointer The solidification microstructure is related to thermal parameters. Black-Right-Pointing-Pointer The segregation behavior is linked to non-equilibrium partition coefficients. Black-Right-Pointing-Pointer The morphology and quantity of carbides depend on the above combined factors.

36 MATERIALS SCIENCE↗
DOE OSTI2014

A comparative study of quantitative microsegregation analyses performed during the solidification of the Ni-base superalloy CMSX-10

Quantitative microsegregation analyses were systematically carried out during the solidification of the Ni-base superalloy CMSX-10 to clarify the methodological effect on the quantification of microsegregation and to fully understand the solidification microstructure. Three experimental techniques, namely, mushy zone quenching (MZQ), planar directional solidification followed by quenching (PDSQ), and random sampling (RS), were implemented for the analysis of microsegregation tendency and the magnitude of solute elements by electron probe microanalysis. The microprobe data and the calculation results of the diffusion field ahead of the solid/liquid (S/L) interface of PDSQ samples revealed that the liquid composition at the S/L interface is significantly influenced by quenching. By applying the PDSQ technique, it was also found that the partition coefficients of all solute elements do not change appreciably during the solidification of primary γ. All three techniques could reasonably predict the segregation behavior of most solute elements. Nevertheless, the RS approach has a tendency to overestimate the magnitude of segregation for most solute elements when compared to the MZQ and PDSQ techniques. Moreover, the segregation direction of Cr and Mo predicted by the RS approach was found to be opposite from the results obtained by the MZQ and PDSQ techniques. This conflicting segregation behavior of Cr and Mo was discussed intensively. It was shown that the formation of Cr-rich areas near the γ/γ′ eutectic in various Ni-base superalloys, including the CMSX-10 alloy, could be successfully explained by the results of microprobe analysis performed on a sample quenched during the planar directional solidification of γ/γ′ eutectic. - Highlights: • Methodological effect on the quantification of microsegregation was clarified. • The liquid composition at the S/L interface was influenced by quenching. • The segregation direction of Cr varied depending on the experimental techniques. • Cr and Mo segregation in Ni-base superalloys was fully understood.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Elemental segregation and subsequent precipitation during solidification of continuous cast Nb–V–Ti high-strength low-alloy steels

In this study, elemental segregation during solidification and subsequent precipitation behaviour in a continuous cast Nb–V–Ti high-strength low-alloy steel was investigated by optical microscopy, scanning electron microscopy with energy dispersive X-ray spectroscopy and thermodynamic modelling. It is known that for steels with low carbon contents the pearlite that forms on slow cooling does so where the interdendritic liquid was present prior to final solidification. The alloying elements of Nb, Ti, Mn and V segregate into the interdendritic liquid during solidification, while Al preferentially segregates into the solidifying solid phase. The composition analysis on the slab samples verified the predicted element segregation behaviour, with a smaller difference in the concentrations of Mn and V in the pearlite and dendritic ferrite regions being observed compared to the Nb levels. Small (30–100 nm) spherical or irregular shaped Nb-rich precipitates (Nb(C, N) and (Nb, V)(C, N)) were mainly found in the pearlite regions, while angular Al-rich (60–300 nm) precipitates were found in the dendritic ferrite regions, in the form of AlN and complex AlN–V(C, N) precipitates. Small isolated ferrite regions surrounded by pearlite were observed in the microstructure and has two origins: one type is dendritic ferrite that appears as an isolated island due to a sectioning effect when observing the two-dimensional microstructure; the other is a ferrite idiomorph that forms in the interdendritic region due to the low carbon content of the steel. Accordingly, in these isolated ferrite islands two different precipitation behaviours are found; predominantly Al-rich particles in the dendritic regions or predominantly Nb-rich precipitates in the interdendritic ferrite idiomorphs. No Al-rich precipitates were observed in the interdendritic regions (pearlite or isolated ferrite idiomorphs) despite the Thermo-Calc predictions indicating a higher volume fraction of AlN in these regions compared to the dendritic regions. This is believed to be due to back diffusion of nitrogen after solidification reducing the available nitrogen, which reacts with the high Nb levels present. - Highlights: • Nb-rich precipitates (Nb(C, N) and (Nb, V)(C, N)) were mainly found in pearlite. • Angular Al-rich precipitates (AlN and AlN–V(C, N)) were found in dendritic ferrite. • Precipitation behaviour in isolated ferrite islands within pearlite was revealed. • Segregation of substitutional elements during solidification is retained. • Back diffusion of interstitial elements (C, N) occurred.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Matching time and spatial scales of rapid solidification: Dynamic TEM experiments coupled to CALPHAD-informed phase-field simulations

A combination of dynamic transmission electron microscopy (DTEM) experiments and CALPHAD-informed phase-field simulations was used to study rapid solidification in Cu–Ni thin-film alloys. Experiments—conducted in the DTEM—consisted of in situ laser melting and determination of the solidification kinetics by monitoring the solid–liquid interface and the overall microstructure evolution (time-resolved measurements) during the solidification process. Modelling of the Cu–Ni alloy microstructure evolution was based on a phase-field model that included realistic Gibbs energies and diffusion coefficients from the CALPHAD framework (thermodynamic and mobility databases). DTEM and post mortem experiments highlighted the formation of microsegregation-free columnar grains with interface velocities varying from ~0.1 to ~0.6 m s –1 . After an 'incubation' time, the velocity of the planar solid–liquid interface accelerated until solidification was complete. In addition, a decrease of the temperature gradient induced a decrease in the interface velocity. The modelling strategy permitted the simulation (in 1D and 2D) of the solidification process from the initially diffusion-controlled to the nearly partitionless regimes. Lastly, results of DTEM experiments and phase-field simulations (grain morphology, solute distribution, and solid–liquid interface velocity) were consistent at similar time (μs) and spatial scales (μm).

36 MATERIALS SCIENCE↗
DOE OSTI2023

The Effects of Silicon and Niobium Concentration on the Solidification Behavior and Microstructure of Cast Monel Alloys

Cast Monel alloys are used in applications requiring a combination of good mechanical properties and excellent resistance to corrosion. Despite prevalent industrial use, relatively few studies have been conducted to investigate the relationships between composition, solidification behavior, and microstructure. Given that these alloys are used in the cast and welded conditions, these factors have a significant influence over the material properties. Here, in this work, microstructural characterization, electron probe microanalysis, X-ray diffraction, and differential scanning calorimetry were used to study how changes in Si and Nb concentrations affected the solidification path and microstructure of Monel alloys. It was found that increasing Nb concentration stabilized higher amounts of MC carbides and suppressed graphite formation during solidification. It was also found that the high nominal concentration and segregation of Si to the liquid led to the formation of Ni 31 Si 12 and other silicides via terminal eutectic reactions at the end of solidification. A pseudo-binary solidification diagram was constructed using experimental data and was applied to predict the mass fraction of solidified eutectic as a function of composition. The modeled microstructures were found to be in good agreement with experimentally measured phase fractions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A transport-based framework for solidification cracking in Ni-based superalloys processed by laser powder bed fusion

Solidification cracking remains a persistent barrier to laser powder bed fusion (LPBF) processing of solid-solution-strengthened (SSS) Ni-based superalloys and is commonly attributed to carbide formation, liquation-type failure, or elemental segregation. In this work, the cracking behavior of three SSS Ni-based superalloys—Inconel 625 (625), Inconel 617 (617), and Haynes 230 (230)—is examined under comparable LPBF conditions to evaluate the origins of their cracking susceptibility. Carbides were present in both 625 and 230, yet cracking behavior differed significantly. MC-type carbides in 625 remain discrete and preserve liquid connectivity, whereas Cr-rich M23C6 carbides in 230 form at cellular triple junctions that bottleneck the interdendritic liquid network, influencing cracking through liquid connectivity rather than as an independent cause. Alloy 617 exhibited anomalous segregation without resolvable secondary phases yet cracked mildly, indicating that extensive carbide formation is not a prerequisite for cracking. To rationalize these observations, a transport-limited framework is proposed in which cracking occurs when terminal-liquid feeding cannot accommodate solidification-induced strain; among the mechanisms evaluated, this framework is most consistent with the physical constraints imposed by LPBF solidification. Transport-based crack-susceptibility indexes incorporating permeability, viscosity, and solidification kinetics distinguish the alloy hierarchy; permeability ratios Krat increased from approximately 7 (625) to 11.5 (617) and 14.5 (230), with corresponding increases in the μ-weighted mushy zone risk index (CSIMZRM). These results are consistent with transport-limited liquid feeding as a rate-limiting contributor to solidification cracking in LPBF-processed SSS Ni-based superalloys, providing a physically grounded basis for alloy and process design.

Hyer, Holden [ORNL] (ORCID:0000000343915561)↗
DOE OSTI2021

In situ synchrotron diffraction and modeling of non-equilibrium solidification of a MnFeCoNiCu alloy

The solidification mechanism and segregation behavior of laser-melted Mn 35 Fe 5 Co 20 Ni 20 Cu 20 was firstly investigated via in situ synchrotron x-ray diffraction at millisecond temporal resolution. The transient composition evolution of the random solid solution during sequential solidification of dendritic and interdendritic regions complicates the analysis of synchrotron diffraction data via any single conventional tool, such as Rietveld refinement. Therefore, a novel approach combining a hard-sphere approximation model, thermodynamic simulation, thermal expansion measurement and microstructural characterization was developed to assist in a fundamental understanding of the evolution of local composition, lattice parameter, and dendrite volume fraction corresponding to the diffraction data. This methodology yields self-consistent results across different methods. Via this approach, four distinct stages were identified, including: (I) FCC dendrite solidification, (II) solidification of FCC interdendritic region, (III) solid-state interdiffusion and (IV) final cooling with marginal diffusion. It was found out that in Stage I, Cu and Mn were rejected into liquid as Mn 35 Fe 5 Co 20 Ni 20 Cu 20 solidified dendritically. During Stage II, the lattice parameter disparity between dendrite and interdendritic region escalated as Cu and Mn continued segregating into the interdendritic region. After complete solidification, during Stage III, the lattice parameter disparity gradually decreases, demonstrating a degree of composition homogenization. The volume fraction of dendrites slightly grew from 58.3 to 65.5%, based on the evolving composition profile across a dendrite/interdendritic interface in diffusion calculations. Postmortem metallography further confirmed that dendrites have a volume fraction of 64.7 ± 5.3% in the final microstructure.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Specimen analysis of the Skylab M553 Metals Melting and Solidification Experiment

The M553 Sphere Forming Experiment conducted in the M512 Furnace Facility during Skylab II was designed to study the effects of weightlessness on the solidification process. Results indicated that there was an outstanding record of solidification terracing and solute redistribution, and that this record may be better than obtainable terrestrially. The solute redistribution was found to be highly localized to prescribed crystallographic systems. It was also shown that for some experimental conditions in a space environment, the anticipated solid/liquid solidification process was perturbed and a solid/liquid/gas reaction took place during solidification. It is felt that these results will contribute to the understanding of terrestrial solidification and will contribute to future space processing considerations.

Larson, D., Jr.↗
NASA NTRS1980

Analysis and calculation of macrosegregation in a casting ingot. MPS solidification model. Volume 1: Formulation and analysis

The physical and numerical formulation of a model for the horizontal solidification of a binary alloy is described. It can be applied in an ingot. The major purpose of the model is to calculate macrosegregation in a casting ingot which results from flow of interdendritic liquid during solidification. The flow, driven by solidification contractions and by gravity acting on density gradients in the interdendritic liquid, was modeled as flow through a porous medium. The symbols used are defined. The physical formulation of the problem leading to a set of equations which can be used to obtain: (1) the pressure field; (2) the velocity field: (3) mass flow and (4) solute flow in the solid plus liquid zone during solidification is presented. With these established, the model calculates macrosegregation after solidification is complete. The numerical techniques used to obtain solution on a computational grid are presented. Results, evaluation of the results, and recommendations for future development of the model are given. The macrosegregation and flow field predictions for tin-lead, aluminum-copper, and tin-bismuth alloys are included as well as comparisons of some of the predictions with published predictions or with empirical data.

Maples, A. L.↗